Means for locating defects in metal articles



A. E. F. BILLs'rElN MmNs .FOR LocATING DEF `CTS 4IN METAL ARTICLES FiledNov. 9, 1940 2 Sheets-Sheet l IIIIII .n..unHU |rn'r ...Tuffi #wwwATTORNEYS. v

March 1o, l1942. A. E. F. BILLSTEIN 2,276,011

MEANS FOR LOCATING`DEFECTS IN METAL ARTICLES Filed Nov. 9, 1940 2Sheetsf-Sheet 2 4 w wf 1;, W

n Y l A TTORNE YS.

Patented Mar. 10, 1942 Arthur E. F. Billsten,'A1too`na, Pa., assignor toThe Pennsylvania Railroad Company, Philadelphia, Pa., a corporation ofPennsylvania Application November 9, v1940, serial No. 364,955

15 claims. (c1. iis-18s) I This invention in its broaderaspects relates.to means for locating imperfections and other defects in metallic bars,shapes, pipes and analogous articles, incidental to production of amagnetic flux locally thereabout and by aid of means responsive tovariations in such iiux.

Devices of the species referred to generally include brushes or the likefor supplying electric current tothe article, at spaced points, to.produce a magnetic field around said article, flaws and otherimperfections being located bya detector unit over-traveling the articlewithin said magnetic field; as well as utilizing sets of detector coilsin conjunction with a conductor eny ergized with current to 0establishan electromagnetic eld. It has also been proposed to determine thepresence of imperfections and so yforth by measuring the current flow orvoltage drop between the spaced points in the rail, while other meanshave been suggested for setting up a magnetic field in the article byelectromagnetic induction. l

The fundamental objective of this invention is a novel means wherebyflaws, fissures and other imperfections within metal rails, bars, shapesand pipes are located by reliance on the earths magnetic eld and theinherent inductive properties of such rails, etc., and measuring theleakage ux at flaws and other imperfections. words, by this inventionprovision is made whereby track rails, bars, etc., can be tested; forinternal and external defects, from end to end without cutting out ordecreasing the testing emciency approximately one foot beyond each endof the joint-bar as is necessary with previous methods. Another objectof this invention is the provision of a novel detector device of theindicated' species, including oppositeIy-wound pairs of coils operativeabove and along one side of the rail head.

A further object is the provisionof a rail iiaw detector mechanismincluding novel means whereby the detector is fiexibly supported from atest car, or trailer truck, said means being operative to move thedetector into and out of coactive relation with respect to the head ofthe rail as required or expedient.

' Other objects with ancillary advantages of l this invention willbecome apparent'from the following detailed explanation of the preferredembodiment thereof shown by the accompanying In other claimsv moreparticularly'dene the features of novelty over prior art.

In the drawings: A Fig. 1 is a somewhat diagrammatic side ele- .vationof 'a railroad track testing or inspection car having the flaw detectormechanism of this invention included therein, and with associateddemagnetizing and marking devices. l

Fig. 2 is a circuit diagram of what maybe termed a natural magneticmeans for detecting transverse imperfections in rail in accordance withthis invention.

Fig. 3 is a longitudinal side elevation of the detector mechanism andconnected means for the resilient supportthereof from a track inspectioncar, certain parts being broken out and others in section for clearerillustration of details.

A Fig. 4 is a staggered end elevation of the preceding gure, or asviewed in the direction of the varrows IV-IV thereon, said figure also'having vparts in section for the better disclosure of' otherwiseobscured structure. i

Fig. 5 is a larger scale detail section, taken y approximately on theplane V-V of Fig. 4.

Fig. 6 is a part side and part vertical section of the detectormechanism, drawn to a further enlarged scale. and as viewedsubstantially within the confines of the plane in'dicating ar- -rowsVI-VI of Figs.l 4 and 9.

Fig. 7 is a vertical longitudinal section on the plane VII-VII in Fig.9.

Fig. 8 isan underside plan view of the detector mechanism drawn to thesame scale as the two preceding figures; and,

Fig. 9 is a transverse section on the plane IX-IX of Fig. 3.

In describing the embodiment of this invention exempliiied in theaccompanying two sheets of drawings herewith, specific terms will beemplcyed for the sake of clarity, but it is to be understood the scopeof said invention is not thereby limited; each suchterm being 'intendedto embrace al1 equivalentswhich perform the two sheets of illustrativedrawings, -wherein like reference characters designatecorrespondingparts in all the views; while the concluding same functionfor an analogous purpose.

Referring more in detail .to the drawings,

Fig. 1 shows a typical adaptation of this in-v vention to a railroadtrack testing or inspection car I, having wheels 2 for traversing therail 3;

said car carrying a surface demagnetizer 4 preferably of the typeforming the subject matter of my prior U. S. Patent No. 2,218,784, datedOctober 22, 1940; a marking device' preferably of the type disclosed ina companion application for patent flied herewith under Serial `Number'to be fully disclosed. This detector mechanism includes the detectorcomprehensively designated 6 and the supporting means 1 therefor, saidmeans being coupled to an appropriate actuator 8 conveniently underoperative control of an air valve 8.

The detector 6, as shown to best advantage in Figs. 6-9, inclusive,comprises an inverted hollow-casing-or shoe I6, preferably ofrectangular contour and appropriate non-magnetic metal, with the majordimension lengthwise of the rail 3, while the ends II of said holder I6are downwardly curved to define arcual shields. In proximate relation tothe shoe ends I I and preferably coaxial with the curvature thereof arestationary shafts I2 with shoe supporting or rail running surfacerollers I3, while said shafts are extended and downwardly angled at I4,inwards with respect to the rail 3, for horizontal rotary supportv ofauxiliary rollers I coactive with the gage side face I6 of said rail,and serving to maintain the shoe I6 substantially centralized lengthwiseof the rail running surface or head. In addition,

as well as inwardly spaced with respect to the shafts I2, the shoe I6 isprovided with planarly -parallel shafts I1, each of which affordsrotative bearing for a rail running-surface roller I8, preferablylocated in the longitudinal median of the .shoe I6; while the inner endsof the shafts I1 hanger members 23, fitted with suitable support-l YAconventional insulate material spacer blocks 21,

held in place by securing means 28, are axially aligned and laterallyspaced pairs of oppositely wound coils 29, 36 in conductivecommunication by leads 3l, 32, of a common cable 33, with. an amplifier8|, Fig. 2, andlater on again referred to. Also in circuit with thecoils 28, 36 in the housing 26 are an aligned pair of similarly woundcoils 34, 36 with associated spacer blocks 36 and securing means 31. Thecoil hook-up just described, as within the shoe I6, is closed-111preferably by a comparatively thin dished nonmagnetic shield-38 held inplace by screws 39, in an obvious manner. This non-magnetic shield 36 isshaped and proportioned to closely approach but never contact therunning surface 46 of the rail 3. The hook-up in the auxiliary detectorhousing 26 is closed-in preferably by a thin multi-ply magnetic shield4I, conveniently held in place by screws 4I', one of said plies 4havingapertured end extensions 42 for eye-connection to the hanger members 23,by the supporting means 24, in a manner closely obvious from Figs. 6 and8 more particularly; while the extension of the service cable 33 betweenthe shoe I6 and auxiliary detector 26 is designated 33' in said ngures,as well as in Fig. 9, for better identification.

Referring again to the several coils 29, 36, it is to be particularlynoted that the respectively associated spacer blocks are' suitablyrecessed at 2,276,011 364,956; and the novel detector mechanism now- 21'for reception of magnetic material channelsection inserts 21", the webportions whereof are over-wound by said coils, whereas the flangeportions project into contact with the inner face of the shield 38, asclearly understandable from Figs. '1 and 8. Similarly the coils 34, 36in the auxiliary detector housing 26 are .provided with correspondingmagnetic inserts 34', 36', with the flange edges directed laterallytowards the gage side face I6, of the rail.3, said inserts alsopreferably not extending downwards into 'abutment with the multi-plyshield 4I,as shown Aby the dotted outline thereof in Fig..6. v

In order to flexibly support the detector means I6 and 26 as a unit fromthe car I, the former is provided with a centrally located flange or web43 projecting upwardly from the top of the shoe I6 land lengthwisethereof. Reference will now be had to Figs. 3 and 4'more particularly,and from saidfflgures it will be seen that the suspension means is ofsomewhat pantographic character, that is to say it comprises a member 44having the lower slotted end 45 pivoted at 46 to the center part of theshoe web 43. The upper end of this member 44 has fulcrumed thereto at-41 a horizontal member 48, in turn supported in the eyeend 49 of asecond suspension member 56, having pivotal connection at 5I to theYfree end .of the longer arm 52 of a bell-crank, fulcrumed at 63 toastationary part or fixed component of the superstructure of the car I;while a slot 64 is provided in the horizontal partl 55 of a bracket 66',

for free passage of said suspensionmember 66. i

Pivoted at 66 to the outer end of the horizontal member 46 is a link 51,normally in parallel with respectto both suspension members 44, 66, andhaving the lower endcoupled at 68 to the shorter arm 58 of a preferablyright-angle leverful crumed at the angular part to a stationary pivot 66conveniently supported across the outer lower diagonal spaced corners ofa framework of rigidly connected vertical and horizontal angle sections6 I. 62 and 63, respectively, with the latter sections 63 securelyattached to the underside of the 'bracket part66 aforesaid.` Thevertical angle sections 6I, 62 are braced and maintained in permanentparallelism by straps 64, while the outer and longer pair 6I of saidsections have rmly mounted therebetween at the lower end, a horizontallydisposed U-shaped guide member 66. 'Ihe normovement by a diametrlc pin13 across said member engaging through a longitudinal sot 14, in theinner part of the plunger 12. The slot 14 also limits telescopicmovement of the plunger 12 relative to the tubular member 68, whilesaidv plunger is furnished with a head 15 and diametricaperturedvextension 16, coupled by a pin' 11 in a longitudinal slot 18through the suspension member 44. Intermediate the plunger head 16 andan adjustable collar 18, held nrmly in place by set-screws 86 to thetubular member 68, is a coil spring 8l in compression; and it is to benoted that the parts just described are initially set by 3, thesuspension member 44, angle-lever arm 66 and link 51 are substantiallyvertical, Whereas the member 48, angle-lever arm 59 and :dexiblecoupling 61 are all similarly horizontal. Thus it will be readilyapparent that, incidental to the pivotal connection, at 49, between .themember 48 and suspension 50,-as well as by the use oftheilexiblevconnectors 2|, positive provision is made for free movementof the supporting means 1 to accommodate lateral shifting of thedetector shoe I and auxiliary detector 26 relative to the rail 3 inrounding curves, swaying of car, and so forth, or straining of thesuspension 58; while the rollers under the iniiuence ofthe spring 8|will always be maintained in contact with the gage face |6 of the rail 3when the detector 6 is in the active position.

Referring now 4to the actuator 8 whereby theA supporting means 1 ismoved from the activeto inactive position, or as indicated by the fulland dot-and-dash lines, respectively,- in Fig. 4, use is made of asuitable cylinder 82, appropriately supported below the floor (Fig. 2)of the car I, in communication with a source of powernot shown-such aspressure air under control of the valve 9, said valve being operativelycoordinated by a rod 83 to a piston 84 in one part of the cylindcr 82.Operative in the other portion of the cylinder 82 is a second piston 85,the rod 86 whereof is coupled at 81 tothe shorter arm 88 A of the bellcrank coordinated with the suspension member 50. The piston 85 isinwardlyinfluenced by a spring 89 of determined strength for flexiblesupport of the means 1 and detectors I0, 26, in the full-line positionofFig. 4, in opposition to the reactive influence of a second spring 90intermediate the pistons 84, 85. Now it will be readily understood, bythose conversant with the art, that when the piston rod 83 is pressureinuenced in the direction of the arrowin Fig. 3, the springs v89, 99will jointly function to move the piston 85 in the same direction,whereby the bell crank 52, 88 will be rocked counter-clockwise on thestationary fulcrum 53 and, though the suspension members 44, 56, movethe supporting means 1,

serts 21" and 34', 35' of the reversely wound coils 29, of thedetectort` and the similarly wound coils 35, 36 of the auxiliarydetector 26, and thence transmitted to the amplier 9| and relay 92, withresultant excitation o f 'said relay to .close the switch 93 and operatethe marking device 5 by current from the battery 94.

, Particular attention is directed to the fact that the shield plate 4|of the auxiliary housing 26 prevents ux coming out from the topv of therail joint bar, lapping* the adjoining ends of aligned rails, resultingin an indication while testing said joint bar area, However, leakage uxat a defect which issues from the side of the rail vhead is not'prevented from passing through the aluminum of .-the auxiliary detectorhousing 26 to be cut by the coils 34, 35,. and thereby permitting, orposiy Atively providing for, examination o f the entire From theforegoing the merits and advantages of this invention will be fullycomprehended and;

while one practical embodiment thereof has been explained in detail inconnection with the acwith the sustained detectors l0 and 26 from thefull-line position to the dot-and-dash one in Fig. 4; whereas, when suchpressure is released a reverse action takes place under the cushioninginfluence of the springs 89, 96 and buiier spring 8|.

Having described the structural aspects of the meansfor locating defectsin metal articles in accordance with this invention, and by jointreference to thediagram of Fig. 2, it is to be noted that in practicethe surface demagnetizer 4 and recorder r are preferably andindividually in independent circuits for A. C. electrical energynotshown-on the inspection car On the other hand, the detectors 6 and 26are in a hookup including the amplifier 9|, a relay 92, switch 93 andbattery 9 4 controlling operation of the marking device 5. Now, as iswell known, each length of rail 3, incidental to the heavy pounding ofrolling stock passing thereover and the earths magnetic eld, becomesmagnetized from end to end with natural flux which remains constant whensaid rail is sound or devoid of faults and flaws. Qn the other hand,wherever a fissure or other flaw occurs in the head of the rail 3, orfaults are exterior thereof, the natural magnetic field will be cut orinterrupted and varied, such variations being picked-up by therespective incompanying drawings, it is to be understood .that saidinvention is not limited thereby but is capable of a variety of otherexpressions, and that changes may be made in the form, construction `and'arrangement of parts, without departing from the'spirit ofsaidinvention. Reference is, accordingly, `to be had to thefollowingclaims `for a definition of the limits and scope of this invention.

Having thus described'my invention, I claim: f

l. Defect locating means for testing rail s'ubf ject to a naturalmagnetic eldcomprisin'g, a

main' detector including spaced vsetsof oppositely wound aligned coilsfor coaction with the rail head top surface, an auxiliary detector withcorresponding-coils coative with the side face of said head and inseries with the rst mentioned coils, and means flexibly .supporting theauxiliary detector in spaced relation to the main detector.

2. Defect locating means for testing rail subwoundaligned coils,eachsaidcoil including a magnetic insert confronting the railhead; an

auxiliary detector with a pair of corresponding coils having similarinserts for coaction with the gage side of the head of the rail; all ofsaid coils being in series; and means flexibly supporting the auxiliarydetector in sp'aced relation to the main detector.

3. Defect locating means for testing rail'subject to a constant naturalmagnetic leld comprising, a main detector with spaced sets of oppositelywound aligned coils, each said coil including a magnetic metal insertpartially confrontingthe yrail head; an auxiliary detector with a pairof corresponding coils having similar inserts, for coaction infpartwith' the gage-side of the rail head, in series with the rst mentionedcoils; means flexibly supporting the auxiliary detector in ilankingparallelism from the main detector, and mechanism for moving the defectlocating means' into and away from conductive influence from the maindetector, and a pantographic system of pivotal members operative tojointly lower and raise the main and auxiliary detectors into and awayfrom inductive iniiuence by the rail magnetic iield.

5. Defect locating means for testing rau sublect to a natural magneticiield comprising, a

maindetector with paralleling'sets of oppositely wound aligned coils andassociated spacers, each said coil having a lapping magnetic metalinsert Y confronting the rail running surface; an auxiliary detectorwith' a pair of corresponding coils having similar magnetic inserts forcoaction with y'magnetic-metal inserts of the main detector extendhorizontally across said detector, and the corresponding coil inserts'of the auxiliary detector are vertically limited to'the gage line regionof the rail head.

8. The combination of claim wherein the I pantographic system o! pivotalmembers includes an angle lever, and an operatively coordinated iiexiblecoupling iects inward and outward angular movement to the detectorsduring the lowering and raising thereof respectively.

. 9. The combination of claim 5, further` charv acterized by a poweroperative actuator for raising the defect locating means to the inactiveposition, and cushion means serves to lower and maintain said defectlocating means in active location with respect to the rail.

10. The combination of claim 5, wherein the main detector consists of aninverted elongated hollow shoe housing transverse freely rotativerollers for coaction with the rail running surface.

axially-aligned laterally-spaced pairsof oppositely wound coils withlapping magnetic metal lnserts iitting recesses in the associated spacerblocks in said shoe, a pair of oppositely wound similar coils in theauxiliary detector housing, and all of said coils are serially wound.

1l. The combination of claim 5, wherein the main detector includesfreely rotative transverse rollers for progressive coaction with th'erail running surface, and the auxiliary detector has similar rollersdisposed for approximate coaction with the gage line of the rail wherebysaid detectors partially surround the rail head.

12. The combination of claim 5, wherein the main detector shoe sets oialigned coils and associated spacers are enclosed by a dishednonmagnetic shield.

13. The combination of claim 5, wherein the auxiliary detector coilhousing is closed in by a. magnetic shield, and means for attachingsaidshield to the coil housing porting members. l l

14. The combination of claim 5, wherein the auxiliary detector coilhousing is closed in by a multl-ply'magnetic shield, the outer of saidplies having eyed extensions Afor attachment' to the iiexible supportingmembers, and means for securing said plies together and to the coilhousing.

15. The combination of claim 5, wherein the main and auxiliary detectorsare made of alumiand to the iiexible supnum, the rail head confrontingsurface of the main detector includes "a non-magnetic shield portion,and a magnetic shield is included inthe auxiliary detector., ARTHUR E.F. BILLSTEIN.

